Method of and means for making castings



Feb. 21,.192s. 1,659,837

` D. J. RYAN METHOD OF AND MEANS FOR MAKING' CASTINGS Original Filed Feb. 23, 1922 6 Sheets-Sheet 1 n J f5 54 o E" 53 as 9 'l 48 Arme/ver e sheets-sheet f2 Feb. 21, 1928.

D. J. RYAN METHOD of' AND MEANS FOR MAKING cAsTINGs original Filed Feb. 2:5. 1922 .n 2/ f 6. n., Ma y m 6 6, 2 3 i wm 2 WJ.: Tua 35s @7M/ i; f a w @a Am. \2 92 5. ,8. am. clik/mv 4 4 Wvlllwa 4. M m4n@ ,w (a my zz .M Ar a5 c l5 i Nw MNANM d .\w\\\ M24 7 m4 w 5 W\\ u 5. f M m Wh ha 4 Z/a .d, w l,10 .d I, N .A A 7 w3 @0MM w M @M 70, 52% @gw 5 7 7 4 3m v W Hl/ w ZIN.. iwf X 5 Z 5 y wx (i 4 L 5 1 M M n w 0 /M w F a W UM 4 7J H4 2 z D. J. RYAN METHOD 0F ANI)A MEANSv FR MAKING CASTINGS Fb. 21, 192s. y 1,659,837

original Filed Feb. 2s. 1922 s sheets-sheet 3 Feb. 21, 1928.

D. J. RYAN METHOD OF AND MEANS FOR MAKING CASTINGS originalmed Feb. 23. 1922 s sheets-Sheet 4 45 El Hummm;

Feb. 2l, 1928. `1,659,837

D. ,.i. RYAN METHOD oF AND MEANS FOR MAKING CASTINGS original Filed Feb. 2s, 1922 s sheets-Sheet 5 y i M llllllllllllllllllllgl//I Fb.z1,192s. 1,659,837

D. J. RYAN 4 METHOD 0F AND MEANS FOR MAKING CASTINGS Original Filed Feb. 25, 1922 s sheets-sheet 6 Patented Feb. ai', 192s.

Unirse s'rArss PATENT OFFICE.

DANIEL J. RYAN, OF CLEVELAND, OHIO, ASSIGNOR TO THE CLEVELAND TRUST COM- PANYgOF CLEVELAND, OHIO, A CORPORATION OF OHIO.

METHOD 0F AND MEANS non MAKrNG CASTINGS.

Application led February 23, 1922, Serial The invention relates more especially to the making of cup-shaped castings such as skirted pistons of the character used in interknal combustion engines. n `Vhile the invention is not limited to the use of metals of any particular class, it is especially useful in the making of castings of light weight metals such as aluminum and magnesium alloys. These alloys have relatively low melting points and are relatively soft, in comparison with iron. The natural softness of these metals makes it desirable to chill themwhen' casting in order to make them harder and give the castings better machining and wearing qualities. Accordingly the most satisfactory j light alloy pistons have been made in Permanent metal molds. 'n

However, the great cost of marking and maintaining the multiple part steel cores of these permanent molds and the diiculty of making such piston castinofs with any but the simplestinterior designs, constitute a serious draw-back to the use of the all-permanent mold., Some attempts have been made to overcome these diiiiculties by the use of permanent mold bodies with ordinary baked sand cores but the resulting savingl in cost was not marked and, in addition, such Abaked sand cores make castings with vrelatively rough interior surfaces, in comparison with castings made with metal cores. The use of green sand cores vin permanent mold bodies also has been considered but, in view'of the desirability of disposing the head kof the piston casting at the bottom of the mold'cavity and the apparent iimpracticability of suspending a green sand core, the useof such cores has not, prior to `my invention, been deemed feasible.

One of the main objects of the inventionl is the provision of a practical method of and means for making and utilizing cores of green sand, or other equivalent material, in permanent mold bodies for casting 'pistons or other cup-shape or deeply recessed objects.

Another object of the invention is the provision of semi-permanent mold .apparatus for the carrying out of a process of casting pistons or the like, in which process the renewal of the frangible, non-permanent core of the apparatus yis effected as No. 538,457. Renewed February 26, 1926.

part of a continuous cycle of steps constituting the process.

Further objects ofk the invention which are more or less incidental to thosev above noted are the improvement of the quality of light alloy pisto-n castings and the reduction of the cost of producing them.

Still other objects, which are more or less incidental or ancillary to those above named, will appear in the following description, as will also the manner of attaining the various objects and the nature of the difculties overcome by my invention. y p

Inasmuch as the Vimproved process of my invention Will bemostY readily explained and understood in connection With suitable apparatus for carrying it out, I will first describe a preferred form of such apparatus as shown in the accompanying drawings, and then will explain the manner in 'which the process is carried out.

In the drawings, Fig. l is a plan view in outline showing a suitable layout of my improved apparatus for use in carrying'out the invention. l

Fig. 2 is a side elevation of the apparatus shown. in Fig. l.

Fig. 3 is a front elevation of the coreforming apparatus including the sandbin.

Fig. 4 is a plan view, on a larger scale, of the multiple cavity core box withA some of the parts broken away and with the core reinforcing rods in position in the core'cavities. n

Fig. 5 is a section on the line 57-5, Fig. 4.

Fig. 6 is a plan view of the core box and the completed cores therein.

Fig. 7 is a section on a line 7 7, Fig. 6.

Fig. 8 is an end elevation of the core box withl the completed cores therein.

Fig. 9 is an enlarged fragmentary section on the line 9-9, Fig. 6. 1

Fig. l0 is a section on the line 10-10, Fig. 6.

Fig. ll is a section on the line 5 5, Fig. 4, showing the means for venting the cores.

Fig. l2 is an enlarged section on the line i2-12, Fig. 4..

Fig. 13 is a fragmentary section on the line is-1e, y l

Fig. i4; 's 'a fragmentary lior'i iital tion showing portion of tli core box bas f of the lcore and secured to the reinforcing rod therein. y D

Fig. 17 is a view similar' to Fig. 16 but with the sides of the core box drawn bach to open position so that the core can .bev

moved. y

Fig. 18 is a plan view of my improved semi-permanent mold.

Fig. 19 is a side elevation of said mold.

Fig. 20 is a fragmentary section on the line 20-20, Fig. 18.

Fig. 21 is a corresponding view taken at right angles to the section of Fi g. 20.

Fig. 22 is a vertical section on the line en -ae, Fig. is.

Fig. 23 is a vertical section on the line 23g- 23, Fig. 18.

Fig. 24 is a vertical section on the line 24u24, Fig. 18. A

Fig. 25 is a vertical section through the core box and the completed cores with my improved core transferringdevice attached to the cores, some of the parts being shown in elevation. i y

Fig. 26 is a plan view of said transferring devicewith the cores suspended therefrom. Fig. 27 is an enlarged vertical section on t-he line 27-27, Fig. 1, with some of the parts shown in elevation.

Fig. 28 is a fragmentary vertical section l on the line 22E-28, Fig. 30.

Fig. 29 is a horizontal section on the line 29-29, Fig. 28.

Fig. 8O vis a vertical section on the brolren line 30-30, Fig. 2S.

:Figa 31 isa view similar to Fig. 30 showing the cla-mp arms open.

Fig. 82 is a fragmentary section on the line 32h32, Fig. es.

F ig. 33 is a vertical section v'through the mold with the core transferring device applied to the cores, some of the parts being shown in elevation. f

l Fig. Sli is a side elevation of the double piston casting made'in my improved mold.

Fig. 35 is a section on the line 35--35,l

Fig. 34.

Referring first to Figs. 1, 2 and 3, the apparatus comprises an elevated bin, 1, adapted to hold a considerable supply of the granular core material, preferably green sand such as is commonly used in making iron and steel castings. Directly in front of the bin 1 is a core box 2 mounted on a suitable bench 3 and adapted for the making of reinforced cores of green. sand. The bin 1 is formed in its front side with a discharge opening 4 which isV fitted with a trough-like discharge shoot 5 adapted to convey sand downward and forward to the top of the core box 2. rlhe shoot 5 is pivotally mounted on a Vrod 6 having at itsV end a counter weight .7 so that after the desired of sand has Abeen drawn down from Y to the core box, the shoot can be turned upward out of the way of the coremalrer.

YThe core box 2 illustrated is provided with two cavities for the simultaneous malring of two cores. When the two cores have been completed, a transfer device 8 is at* tached to them by the coremalrer and, suspended from this transfer' device, they are lifted by thecoremalrer and placed upon the rack 9.

Adjacent the core rack 9 are two molds, 10, 10 mountedfon suitable benches 10a,y 10a and each designed to be operated by one person. riihe mold operator lifts a pair of amount i the bin 1 cores from the rack 9, lowers them into lthe two cavities of the mold 10, and, after securing the cores in position, forms the castings by pouring into the mold molten metal dipped with a ladle from a heated holding pot 11. As rsoon as the molten metal is solidified in the mold cavities the mold is opened, the casting removed, the cores thereof broken, out and the reinforcing parts of said cores passed back to the coremalrer for re-use, thus completing the cycle of operations.

With this brief outline of the apparatus and procedure in mind, the several'V parts of the apparatus will now bel described in further detail. i Y Y The core box 2 which is illustrated in detail in Figures 4 to 17,`inclusive, is designed to simultaneously produce two cores for piston castings. Said box comprises a base .12 upon lwhich are slidably mounted two side Vmembers 13, 111. The base is provided with twoy guide rails 15, 15V and the-bottom sides of the side members are grooved to lit these rails so that the sliding i'i'iovement of the side members is guided on right lines. To facilitate their movement manually he sideA members are provided at their two ends with handles 16, 16. The side member 13 is formed 'on its inner face with two recesses 17, 18 and the side member 1e is formed with a similar pair of recesses 19, 2O which mate with the recesses 17, 18, respectively, and thus form the side walls of the two open topped cavities of the core box. f

On the side walls of the two cavities are formed inwardly projecting' bosses 21, 22 corresponding to the wrist pin bosses to be formed on the piston casting. The inner side walls of the core box cavities are alsoY lll) sin)

ing cylindrical bosses 24, 24 which are spaced apart the same distance as the two core box cavities and serve to form the bottom wall of said cavities.l Each boss 24 is formed with a diametrically extending slot 24a in which the two fingers 23 of the side members fit.

The bosses 24 are preferably formed as sepa-A rate cylindrical blocks and are secured in recess in base 12 by means of screw bolts 25 and dowel pins 26. As is shown by the en` larged views on sheet 3 of the drawings, the side walls of the core box cavities are formed with circumferential lillets 27 where said side walls join the upper edges of thev bosses 24. One advantage of the upstanding bosses 24 is that the lillets can be formed above the bottom edges of the side members of the core box and thin metal` edges at the lower sides of said fillets are thus avoided. Said bosses also make possible the use of the substantially formed finger extensions 23 so that the ribs 23a can be strongly supported and made continuous from the axis of the core cavity up to the wrist pin boss recesses.

Thebase 12 and side members 13 and 14 of the core box can be made of any suitable form substantially circulaiopenings coaxial.`

with the core box cavities and serve a pur-V pose which will presently be explained. rlhe side members 13 and 14 are provided Vat their rightends with upstanding guide pins 32, 32 which engage bushed openings 28,

29" in the plates 23, 29 and serve to accurately position the rightends of the plates 23 and 29 when the latter are lowered on the side members 13 and 14.

The side member 13 carries on its inner side dowel pins 33 which engage holes in the adjacent face of the side member 14. Thus, the engagement of the side members 13 and 14 with the rails 15 and with the upstanding bosses 24 and the .engagement of said sido membersr with each other through the dowel pins 33, serve to accurately align said side memberswhen they lare brought together. To lock the side members together hooks 34, 34 mounted on the ends of the side member 14`engage pins 35", 35 on the ends of the side member 13.

1n the production of reinforced green sand cores by means of the core box 1 proceed as followsz-The side members of the core box are brought together and locked by hooks 34. The'plates l23 and 29 are then swung over off the side members as shown in Fig. 11, the bench 3 being preferably provided with a support 36 for said plates. l then introduce into each core cavity an upstanding rod 37. This rod is formed at its lower end with a liange 37 having on its under side a slot or groove 37bV which lits the ribs 23u on the finger extensions 23 of the side members. Near its upper end each rod 37 is formedwith acollar having an upwardly facing shoulder 37c disposed in the same plane as the top surfaces lof they side members 13 and 14. Above the shoulder 37c the rod 37 is formed with screw threads 37d. When the coremaker has set up the rods 37 in the cavities, placing them approximately at the'centers of said cavities, lie-next pulls down sand shoot 5 and with his hands draws from the opening 4 sand to lill the two cavities, pressing the sand in around the rod 37 and the bosses 21, 22with his fingers in a manner readily understood by those skilled in this vart. ill/'hen the cavities have thus been lled with sand the top surfaces of the core bodies are struck off evenV with the rod shoulders 37C and the top surfaces of the side members 13 .and 14, as shown in Fig.. 11,y thus complet- `ing the formation of the franglble granular core body 33. In striking off the sand a smallmetal plate or stripor any suitable form of straight edge can be employed.

The green sandrcore bodies thus formed are next properlyv vented. To accomplish this easily and quickly 1 preferably provide a venting fixture designated in its entirety by 39, sce Figs. 1, 2, 3, aud 11. This lix ture comprises a plate 3911 with two pairs of depending pins 39h and two depending guide rods 39C which are adapted to engage tubular vguides 40- mounted in the ends of the core box base 12. The fixture 39 is conveniently suppbrted by cords 41 which pass over guide pulleys 42 and 43 mounted .on the top of the sand bin 1 and are secured at their other ends to a counterweight 44. When the coremaker desires -to vent the cores it is only necessary for him to draw the fixture 39 downward. bringing the rods y39C into register with the guide tubes 40,

Vin Fig. 6 and plate-like metal core prints are placed in position on the tops of the sand bodies of the cores. Each print 45 is provided with a central aperture 45"' adapted to pass over the upstanding threaded end of the rod 87. The periphery of cach print is formed to fit the recesses 30,- 3l of the top plates 28 and 29 and each print definitely positioned angularly by notches 451 therein which engage correspondinc' projections 28h, 29b et the top plates. in position, are lirmly secured to the reinforcing rods 37 by means of wing nuts 46. rlhus con ected, the rod or anchor 37 and the plate or arbor constitute a rigid corereinforcing structure with `a part thereof embedded in the sand body of the core and a part engaging the upper portion ot said sandvbody and exposed so as to constitute a metallic core print adapted to engage the metal walls of the mold body, as hereinafter described. The prints 45 are Jformed with arcuate openings 45c which overlie the vent passages 38 and insure 'tree egress of vapor and gases from said passages.v

l/Vith the core prints 45 applied to the cores, the side members i3 and 14 of the core boXcan be moved rearward and torward, respectively, thus leaving the finished cores standing on the bosses 24, as shown in F ig. 17. To 'facilitate the handling of the cores, I have devised a core transferring device illustratedin Figs. 25 to 30. rlhis device, designated as an entirety by 8, comprises a skeleton plate or trame 48 formedv with a central opening 48, elongated end .openings 48b and with end extensions 48".

Near each end the frame 48 is provided with anupstanding bracket 49 and on these brackets is mounted a longitudinally extending rod 50. On the rod 50 over each of thefogenings 48b is mounted a tongs-like clamp 5l 'which comprises two lever arms 51a, 5lb which are mounted to turn on the rod 50 but arefheld against axial displacenient by adjustable collars 52, 52. rlhe lower ends of the arms are formed to engage traine as indicated in Fig. 3l and are also formed with jaws dtlapted to embrace the atjacent wing nut 46 of the kcore structure, while the upper ends oit said arms are 'formed to. be engaged by the tluiunb and. linger ol the operator to expand the lower ends ol' the clamp against the tension ot a coil spr-ing 51C.

Vhen' the cores have been formed in the manner above delicribed thetransi'er device 8 can be attached to the reinforcing structures of the cores as shown in Figs. 25 and '30.' To do this the coremalter simply eX- pands the clamping arms 51a, 51b so that the latter will pass over the wing nuts 46 as shown in Fig. 3l. l/Vith the plate 453 of the vtransfer device resting upon the core prints lhe prints 45, having been placed resaca? 45 the clamps are then released bythe coremaker so as to allow them to grip the wing cores to be clamped snugly between the un- Y der side ot the plate 48 and the tops ofthe jaws of the clamp arms 51a, 5l.

rlhe transfer vdevice having vbeen attached to the cores, the core boli is opened and the cores can then be itreely lifted by means ot' the transfer device and placed upon the supporting raclv 9 shown in Figs. 1,-2 and 27. The brackets 4l) of the` traniiery device serve as handles igor convenient lifting ot the cores.

ln Fig. l, two o1 the molds l0, 1.0 are shown, each being mounted' on a suitable bench 10, as these molds are alike a description of one will suiiice for bothot them. The body ot the mold consists essentially of two side members or halves 53, 54. The ad-v jacent or abutting faces ot the moldhalves are formed with recess-es to provide two castcavities 55, 56 and an intermediate gate cavity 5'?. The gate cavity is providedwith a suitable pouring mouth by upstanding eX 'tensions 5S formed on the mold halves. The

gate cavity 57 communicates with the cast-1 ing cavities tromlthe bottom to substantially the tops or" said cavities through narrow passages 59, 59, the width and thickness of the gate cavity being relatively large in comparison with the thickness of the mold cavity proper, so that the metal in the gate cavity necessarily is the last to freeze or set when the casting has been poured. At theV can be positioned to permit the lowering ofV the core into the mold body. By turning tho wing nuts down over the edge or" the core prints, as shown, the latter are securely clamped in position.

l/Vith the cores in position, as .shown in Fig. 22, it willbe noted that the core print forms the upper annular wall ofthe casting cavity. To permit free exit ot vapors and gases from the casting cavity during the pouring, the side and bottom surfaces of the core prints are formed with venting grooves 45d. I prefer in some instances to form the side walls of the mold cavity with circumlierential ribs 62 in order to form ring grooves on the sides of the piston casting. rllhese ribs are of a form and shape to leave on the casting a small amount of metal to be cut away in machining the grooves; By

loo

To facilitate the lowering of the cores into the mold, the mold halves` are provided on their upper sides with upstanding guide posts 6e, 6i which are adapted'to lit the notches 45h of the core prints. The posts 64 are rigidly secured to the mold halves by screws 65.

rilie inold halve-i may be made of cast iron and are preferably formed with top walls 53a, fida, bottom walls 53D, 541 and end walls 53C, 5de. rihere are also vertical strengthening ribs 53d and 54d extending between the said top and bottom walls.

The mold halves can be supported for movementtoward and from eachother in various ways. n the preferred construction shown a supporting frame and mechanism for moving the two mold halves toward' and from each other, are provided. The frame has castend plates 66, G6 formed with bases or pedestals 66a, 66a adapted to rest upon the bench. These end plates are connected by a bottom plate-like casting 67 to which they are secured by screw bolts 68. The end castings 66 are also connected by a pair of round top bars 69, 69 and a pair of bottom cross bars 7G, 70. At the front side of the mold, a pair of slides 71, 72 are mounted on the rods 59, 70 and at the rear side of the mold aresimilarly mounted a corresponding pair of slices 73, 7d. The mold half 53 is rigidly secured to the slides 71, 7 3 by screws 75 and the mold half 54 is similarly connected to the slides 72, 7e by screws 76. In addition to the support afforded the mold halves by the slides, said mold halves also are slidably supported by the bottom plate 67 of the frame.

'llo facilitate the opening and closing of the mold halves the frameV rods 70,V 70 are E:orzned on their under sides withvrack teeth 'O ln suitable bearings on the slides 71, .3 is mounted a shaft 77 and on 'the slides 7 `741- is similarly mounted a shaft 78. Each of these shafts is fitted with pinions 79 which mesh with the rack teeth 7 (la. Hand wheels 8O are mounted on the front ends of the shafts 77 and 784 and by turning these wheels, the mold halves can be moved toward or from each otheron right lines, as will readily be understood.

ln utilizingmy invention for inaking piston castings, l prefer to core outthe wrist pin bosses. For this purpose. I slidably mount a pair of core pins 81 and a similar pair of core pins 82 in the mold halves 53 and 5%, respectively. These pins are arranged so that one pair of pins 81, 82 projectiinto one of the cast-ing cavities while the other pair project into the other cavity, in' the manner indicated in TEig. 23. When these core pins are in the positions shown in F ig. 23,-their inner ends engage the body 38 of the core.v Y'lo facilitate the withdrawal of the core pins from the castings the inner ends of the said pins are tapered as shown. Each vof the pins is formed on its under side vwith rack teeth 8l'LL or 8 The rack teeth 81L are engaged by pinions 83 on a trans-l verse-shaft 83 mounted in the slides 71, 73 while the rack teeth 82a are engaged by pinions 84a on a similar shaft 84 mounted in the slides 72, 7e. The front ends of the shafts 83, 8st are provided with hand wheels 85 and both core pins in each mold half can be simultaneously moved inward or outward` in relation to the mold cavity by simply turning one of said hand wheels.

To insure accurate alignment of the two mold halves when they are brought together the mold half 53 has its inner face fitted with dowel pins 86 and the opposing face of the mold half 54 is formed with holes to receive said pins. 1When the mold halves are brought together they can be firmly locked bymeans of hooks 87, 87 on the ends of the mold half 5e which engage lpins 88, 88 on the ends of the mold half 53.

In carrying outmy improved process of forming cup-shaped castings, 'by means of the apparatus above described, the 'following cycle of operations is performed. vA core maker standing at the bench 3 of the core box forms a pair of cores by introducing the core reinforcing rods and the sand into the core box cavities, striking oftq the tops of the core bodies, venting saidcore bodies and 'applying'vthe core prints thereto, in the manner previously described The core maker then applies the transferring device 8 to the cores, separates the core box and lifts the pair of cores over to the support-ing rack 9. A mold operator stationed at one of the molds 10 having meanwhile closed his mold and locked it and moved the core pins 8l, 82 to their outer positions, lifts the pair of cores from the rack 9 by means of the transferring deviceV and lowers said cores into the mold cavities where they are accurately 'positioned and supported by means of the, core prints, it being understood thatthe upstanding guides 6 4! of the mold insure a proper angular disposition of the boss recesses of the cores in vrelation to the core pins 81, 82 of the mold. VThe'cores having been lowered to position in the mold, the transferring device is detached from the cores and returned forre-use by the core maker. The cores are then rmly lsecuredV in the mold cavities byy means of the clamping nuts 61. Then the hand lwheels 85 lare turned to move the core pins 81, 82 to their innermost position. Thereupon the mold operator with a suitable pouring ladle dips molten metal, such as aluminum alloy,

ril)

mold.

vfrom the heated holding pot- 11 and pours the metal through the gate opening 58 of the The molten metal is fed from the gate cavity 57 into both of the mold cavities 55 and 56 to simultaneously form two castings, the metal to form the head part of the piston casting 'entering the b ottom of the casting cavity directly from the gate.

As soon as the initial solidification of the 'y poured metal occurs (as indicated by the gate metal, can be lifted from the mold.

The green sandcores are readily broken out of the castings, whereupon the reinforcing structure comprising the rods land core prints are passed back to the core maker for re-use.

As one capable core maker can make cores rapidly'enougli to supply two molds I prefer to arrange the apparatus as shown in Fig. l Awith the two molds l() conveniently dis- Aposed in relation to the rack 9. It is also preferable to provide a helper to pass the transfer devices back to the core maker and to break out the cores from the castings and pass the core rods and prints baci to the core maker. With the apparatus arranged as in Fig. I, the core maker finds it convenient to place the pairs of cores alternately on the two ends of the rack 9 in convenient reach of the respective mold operators. The molten metal holding pot 11 is conveniently placed with respect to both of the molds.

It will be seen that the cycle of steps constituting the process includes the repeated renewal of the frangible cores andV that this renewal is effected as the cores are required in the cycle.

As is well understood in connection with the operation of metal molds, the mold body 4absorbs considerable heat from the molten metal poured into the `mold cavity to form the casting. rlhus, when my mold is first placed in operation, the first two or 'three castings poured ser-ve to heat the walls of the mold and as the mold is continued in operation the heat absorbed from the molten' metal from each casting serves to heatthe metal mold for the subsequent casting or castings poured. Y

The two-piston casting made by the particular form of my apparatus herein disclosed is shown in Figs. 34 and 35. lit will, of course, be understood that the designs of the core and mold body can lbe varied to produce piston or other deeply recessed castings of a wide variety of forms. The individual piston castings are, of course, to be separated from the gate metal by breaking or by means of a saw or other suitable cutting` tool.

'The castings formed by my improved process have suitably chilled walls. At the same time the frangible sand cores make it p possible to cast piston or other cup-shaped castings with various forms of internal projections which would make the casting of said articles in all-permanent'molds impossible. By forming and supporting the frangible cores in the mannerrdescribed 'I have found it possible to produce cores with ordinary green molding sand which are adequately strong to withstand all of the necessary handling involved in the cai'-l rying out of my process of casting. Furthermore, I produce cored castings with the smooth interior finish characteristic of 'green permanent molds because the steel cores ofl said permanent molds do not permit ther casting to shrink freely.

YIn the making of light alloy piston castings in chill molds it is important that the head of the piston be at the bottom of the mold cavity where the molten metal directly enters, for this insures a densenon-porous structure in the head ofthe piston.V Alt-- teinpts have been made to cast light alloy pistons in permanent mold bodies with the .in old cavity otherwise disposed, as with the piston head uppermost, but these attempts have not been successful probably becausel the molten metal isv in such cases forced to flow over extensive chilling surfaces before it reaches the top of the cavity and porosity results.

due to the fact that my improved green sand cores are adapted to be suspended in open top mold cavities so that the head of the pistonv is disposed at the bottom of the cavit It will of course. be seen that with my process the casting cavity isnot- Vonly. freely vented from the top thereof through the grooves formed in the metal parts of the mold but also through the porous bodyV of the core. Consequently, a freer venting is secured than is possible with all-permanent molds. f

It is possible to produce green sandv cores, such as I have described, with such ease and t l y t tl t T bl lb at so ow a cost ia i am ena ec y my improved process and apparatus to produce iio I believe that the suc-v cess ot my' process is in no small measureV i light alloy piston casting that are `more uniformly of high quality than those produced by all-permanent molds and at a cost substantially lower than is possible 'With either the all-permanent mold or the semi-permanent mold With'baked sandv` cores.

While I have shown and prefer to use a core reinforcing structure made up of separablel parts, in certain of its broad aspects the invention can be practiced With a unitary reinforcing structure. Of course, by having the print section separable from therod'section of the structure, greater freedom is allowed in pressing the sand intofthe core box cavity, and this advantage is especially important in the case of small size pistons; with pistons of large diameter a unitary reinforcing structure .becomes more feasible.

Furthermore, it is to be understood that the particular forms of apparatus shown and described and the particular procedure set forth, are presented for purposes of explanation and illustration andV that various modifications of said apparatus and procedure can be made Without departing from my invention as defined in the appended claims.

What I claim is:

l. The process of makingrecessed cast-` Vto form .the casting.

2. rlhe process of makingkcup-shaped castings Which comprises forming a. core of moldable granular material With 'internal reinforcing means extending to the top of the core, thereafter applying a rigid nonfrangible core print to the top of the core and rigidly securing said print to said internal reinforcing kmeans in predetermined 'relation to the core body, introducing the core into the opentopped cavity of a permanent mold With said print engaging the mold body and maintaining the core suspended and properly positioned in the mold cavity, and introducing molten metal into the mold 'through a gate leading into the bottom 0f thetmold cavity.

3. rIhe process of making cores for cupshaped castings which comprises positioning reinforcing means in the cavity of a core box, pressing moldable core material into said cavity around the reinforcing means so as to form a. frangible core body of on the bottom of a core box cavity, pressing moldable core material into said cavity around the reinforcing means so as to form a frangible core body of definite form' and size with the reinforcing means extending above its top surface, thereafter applying a non-frangible core print to the top of said core body, and rigidly securing said print to the reinforcing means in predetermined relation to it and to the core body.

5. The process of making cores for cupshaped castings which comprises introducing into the opeirtopped cavity of a corevbox an upright reinforcing rod With its lower end resting onthe bottom Wall of the Cavity and 'an upwardly facing shoulder onV its upper partdisposedA at a predetermined level in relation to a top Wall of the core box, packing into the cavity around said rod moldable core material, striking off the top of said material to a definite formin relation to said shoulder, placing an apertured non-frangible core print over the yupstanding end of said rod with the under side of the print contacting With the said shoulder and the top ofthe core, securing said print to said rod in firm engagement with its shoulder, and removing the core'from the box.

6. The process of making cores for cupshaped castings which comprises introducing into the open-topped cavity of a core box an upright reinforcing rod with itsloiver end resting on the bottom Wall of the cavity and an upwardly facing shoulder on its upper part disposed at a. predetermined level in relation to a top Wall of the core box, packing into the cavity around said rod moldable core material, striking olf the top of said material to a definite form inrelation to said shoulder and top Wall placing an apertui'ed non-frangible core print over the up'standing end of said rod With Vthe under side of the print contacting with the said shoulder, top Wall and tlietop of the core, securing said print to said rod in firm engagement fith its shoulder, and removingthe core from the box.

7. In apparatus -for making recessed castings, the combination of means forforming a core that comprises a frangible body of moldable granular material with internal reinforcing means of non-frangible material extending above the top surface of said body, a permanent mold body with an opentopped cavity adapted to receive said core, and a core transferringy devicey adapted to llO detaclialily engage the top part of the' nonfrangible core structure and hold the core suspended while it is ,being transferred lfrom the core-forming ineans to the mold.

'8. In apparatus for making recessed castings7 the combination of a core box for simultaneously forming a plurality of cores of which each comprises a franpgiblebody of molduble granularmaterial with internal reinforcinp,v means of non-frangible material extendingv above the top surface of said body, a permanent mold body formed with a plurality yof open-tojiped cavities adapted to receive said cores, and a core-transferring` device adapted to detacliably the top arts of the noii-frangible core structures and hold the cores suspended While they are being simultaneously transferred from tbe core-forming` means to the mold.

9. In apparatus for making recessed castings, the combination of a core box for simultaneously forming' a plurality of cores of which each comprises a franeible body of moldable granular material with internal re-v inforcing means of non-frangiblc material extending above the top surface of said body, a permanent mold body formed with a plurality of open-topped cavities adapted to receive said cores, and a coretransferring device comprising a frame and a plurality of lmanually operable clamps adapted to detacliably engage the top parte of the nonfrangible core structure and hold the cores suspended While they are being` simultaneously transferred from the core-formingmeans to the mold, said clamps being adjustable toward and from each other to accommodate core boxes and molds of different sizes.y

10. In apparatus for formingcastings, the combination of a core box with a pair-of open-toppecl cavities adapted for the formation of a pair of cores of which each comprises a frangible body of moldable granular material with internal reinforcing means of non-frangible material extending above the topl surface of said body, a permanent mold body formed withr a pair of opentopped cavities spaced the saine distance apart as the core box cavities and adapted to receive said cores, and a core-transferring device adapted to simultaneously detacbably engage the non-frangible top parts of two cores in the core box and hold tliein suspended While tliey are transferred to and lowered into the cavities of the 'mold body.

1l. In apparatus for malrinfgr recessed castings, tlie combination of* means for forming a core that comprises a frangible body* of inoldable granular material lwith internal reinforcing Vmeans of non-frangible material extending above the top surface of said body, a permanent mold body with an open-topped cavity to receive said core, a core transferring device adapted to detachably engage the transferring device lwith a lcore suspended therefrom. s Y 12. In apparatus for making recessed castings, the combination of acore box adapted for the formation of cores of inoldable rgranular material with non-frangible internal reinforcingmeans extendingv to their top suri faces, means for delivering such granular material to the core box, a permanent mold body,having` an open-topped cavity adapted to receive one of said cores, a coretransfer ring device adaptedto detacliably engage the top partV of the reinforcing structure of a core and hold the core suspended While it is being' transferred from the core box to the mold cavity, and means adj acont the core box and the mold for supporting said transfer device with a core suspended therefrom.

13. In apparatus for making recessed castings, the combination of a coreV box adapted for the simultaneous formationvof Va pair of cores of inoldable granular material with non-frangible internal',reinforcing means extending to their top surfaces, means for deliveringsuch ygranular material to the core box, a permanentmold body having a pair of open-topped mold cavities spaced apart f substantially the same distance as the core -c vities of the core box and adaptedvto recei ve a pair of said cores, a core transferring `device adaptedto detachably engage the top parts of tbe reinforcing structure-s of a pair of cores in the core box and to hold Said coros suspended While they are being transferred from the core box to the mold cavity, and means adjacent the core box and the mold for supportingy said transferring device with itsoores suspended therefrom.'r Y' 14. Iii-apparatus for making" recessed castings, the combination of a core box adapted for the vformation of'cor'es of moldable granular material With non-frangible internal reinforcing means extending to their top surfaces, means for delivering such granular material to the core box, two similar permanent mold bodies each having an'open-topped.

cavity adapted to receive one of vsaid cores, core transferring` devices cach adapted to detachably engage the top part of therein! forcingjstructure Vof a corefand hold said core suspended, and means near the core box and the two mold bodies forsupporting said transfer' devices with cores suspendedtherefrom.

15. In apparatus for making frangible cores With non-frangible reinforcingv structures, the combination of a base, a pair of lim iio

abutting side members movable toward and from each other over the base and having their adjacent faces recessed to forin'the side walls of an onen-topped cup-shape core cavity the bottoni Wall of which is formed by the base, and guiding means for causing the side members to move on definite lines relative to each other. Y

16. In apparatus for makingv frangible cores With non-frangible reinforcingstructures, the combination of a base, a pair of abutting side members movable toward and from each other over the base and having their adjacent faces recessed to form the side Walls of an open-topped cup-shaped core cavity the bottom Wall of which is formed by the base, and means on said side members for definitely positioning in relation to said cavity a non-frangible core print to be attached to the core body.

17. In apparatus for making frangible cores With non-frangible reinforcing structures, the combination of a base having thereon an upstanding boss adapted to form the bottom Wall of an open-topped cupshape cavity, and a pair of abutting side members movable toward and from each other over the base and having their adjacent faces recessed to embrace and fit the sides of said bossv and toform'the side Walls of said cavity, the said side Walls being formed Withlillets WhereV they join' the Stop surface of the boss.

18. In apparatus for making cores for piston castings of frangible material with non-'frangible reinforcing means, the com-v bination of a base having thereon an upstanding boss adapted to form the bottoni Wall of an open-topped` lcup-shape cavity, said boss being formed With a diametrical slot, and a pair of abutting side members movable toward and from each lother over the base and having their adjacent faces recessed to embrace and fit the sides of said boss and to form the side Walls of said cavity and each side member having a linger extending radially into thev slot in said boss and forming a rib extending upward from the top surface of said boss..

19. In a mold for forming cup-shape castings, the combination of a metaliic mold body formed with an open-topped cavity, and a core suspended in the cavity, said -core having a frangible body of green sand .and a rigid metallicreinforcing structure coinprising a portion embedded in said core body and a print portion engaging the ups per portion of the core body and engaging the mold body so as to hold the core suspended in the mold cavity in predetermined spaced relation to the Walls thereof.

20. In a mold for forming cup-shape castings, the combination of a metallic mold body formed With an open-topped cavity, and a core suspended in the cavity, said core having a frangible body of green sand and a rigid metallic reinforcing structure comprising a. portion embedded in saidcore body andextending to the top thereof and a print portion engagingthe upper portion et the core body and rigidly detachably securedvto the embedded portion and engaging the moldbody so as to hold the core suspended in the mold cavity in predetermined spaced relation to the Walls thereof.

21. In a mold for forming cup-shape castings, the combination of a permanent mold body formed with an open-topped cavity and a core suspended in the cavity, Vsaid core having a frangible body of green sand and a rigid metallic reinforcing structure comprising a portion embedded in said core body and a print portion engaging vthe npper portion of the core body and engaging the mold body so as to hold the core sus pended in the mold cavity inpredetermined spaced relation to thewalls thereof and with almetal part of the mold structure forming the annular top Wall of the cup-shape cavity of the mold.

22. In a mold vfor forming cup-shape castings, the combination of a metallic mold body formed withl an open-topped cavity, and a core suspended in the cavity, said core havinga frangible body of green sand and a rigid metallic reinforcing structure comprising a. portion embedded in said core body and a print portion engaging the upper portion of the core body and engaging the mold body so as to hold the core .suspended in the mold cavity in predetermined spaced relation to the Walls thereof and WithV the under side of said print sec-tion forming the annular top Wall of the cup-shape cavity of the mold.

23. In a mold for forming cup-shapey castings, the combination of a metallic mold body formed with an open-topped cavity, a core suspended in the cavity, said core having a frangible body of'green sand and a non-frangible rigid reinforcing structure comprising a portion embedded in said core body and a print portion engaging the upper portion of the core body and engaging the metallic mold body so as to hold the core suspended in the mold cavity iii/predetermined spaced relation to the Walls-thereof, and means to secure the core print sectionv in position relativey to the mold body.y

24. In a mold for forming a'piston casting, the combination of a metallic mold body comprising two side sections movable to- Ward and from each other and recesses on their adjacent faces to form outer Walls of the mold cavity, a core suspended in the cavity, said core having a frangible body of green sand with oppositely disposed pin boss recesses and a rigid metal reinforcing structure' comprising ak portion embedded in said core body and a print portion vengaging theupper portion ofv the core body and the mold body so as to hold the core suspended in the mold cavity in predetermined spaced relation to the Walls thereof and core pins slidably mounted in the halves so as' to be. moved eiidwise into and withdrawn from the said pin boss recesses.

25. In a mold for formingpiston castings, the combination oi a permanent moldbody comprising` two side sections movable toward and from each other and recessed on. their adjacent taces to. 'form outer walls oit the mold cavity, a core suspended in the cavity, said corefhaving a irangible body of moldable granular material with oppositely disposed pin boss recesses and a non-:trangible reinforcing; structure comprising a section embedded in said core body` and extending tothe top thereof. and av print section. at the upper end ot the body secured to the embedded sectionand engaging the mold body so as. to hold. the core suspended in the moldcavity in. predeterminedA spaced relation to the Walls thereof, andl core pins slidably mounted. in. theI moldv halves so.v as tol be moved endwise into.y and withdrawn from the said pin. boss recesses.

26. In: a mold for tormingpiston. castings, thecombination of' acpermanent mold body comprising. two side sections movable towardiA and trom eachother and having. on their. adjacent faces ay plurality oif pairs ol ii'iatingrec'esses to :torniouter walls ot aplurali-ty of. mold' cavities7 ,cores suspended in saidcavities, each core having oppositely disposed pin boss recessesaplurality ot core pins slidablyy mountedl in each. mold 'halt to be lmoved. endwise into andf withdrawn trom the said pin boss recesses, and means mounted on, each. moldV side section. for simultaneously moving 'thev core pins mounted thereon..

27. Inmolds for. making cup-shape castings,- tlie combination. o..a.mold.: body termed with` an open-'topped cavity,.and a coi-e sus* pended. therein'. said core having. a green sand. body and. a Y non-'frangible reinforcing structure comprising. an upright elongated section with a flange on its lower end'v toi-ming( part ot: the bottomsurtace ot the vcore andy a-plate-like print .section secured to the upper` end of the elongated section and firmly engagingithe topy portion oi the green sand body..

28; In. molds lor makingcup-shape castings,thefcombination of a moldbody formed withanopenftoppedcavity, and acore suspended therein,V said. core havinga green sand! body and anon-trangible reinforcing structure; comprising an. upright elongated section with. a-.lange on itsnlower .endt form ingr-partici? thebottoin surface of the core and.Y an. upwardly facing. shoulder at its upper. end.y and .a vplate-likeprint section rest ing onsaidshoulder. and thetop of the green sandfbody and lirmly secured to said` elongatedb'ody; y i

29. Iii-a'fmoldorforming cup-shape castings the combination ofl av metallic mold body formed with an open-topped cavity,

prising a portion embedded in said core body V anda print portionengaging the. upper portion of the core body and'rigidly detachably secured to the embedded portion and engagingthe mold body so as to hold theV core suspended in the mold cavity in predetermined spaced relation to the walls thereof.'

30. A mold for the casting` ot hollow ar.- ticles o't'aluminum or like meta-ls comprising an arbor for supporting a green sand core and a sectional outer mold provided With' a seat for receiving said arbor with the core suspended therefrom withinlthemold cavity.

3l. An apparatus for the formingoi cast articles. of' aluminum and like metals comprisingp a mold for the` forming ot' a green sand core, an arbor for supporting the core seated .upon said moldand provided withmeans tor accurately positioning the saine withfrespect thereto andan outer casting mold having. a' seat for receiving said arbor,V and corresponding means tor positioning the same with the core suspended in accurate registration within the mold cavity.

32. An apparatus for forming;` cast articles otaluminum and like metals'comprising` .a mold tor a green sand core having'a tapers ing arbor receiving seat, an arbor for engaging said seat provided; with means for accurately positioning` the same in lrelation to the mold cavity and also provided with a` proj ectine.` anchor around which the sand is impacted, a sectional outer casting-:mold provided with a seat'tor'receiving saidfarbor corresponding to the scat-inV said core mold and adapt'edto accurately positiontlie green sandI core Within the mold'cavity.

33. AnV apparatus 'loiftorn'iingij cast articles Otaluminum andlike metals, comprisingrr an arbor, means for forming a' green sand core supported from said arbor. a: casting' inoldf and tguidinaf-means on said casting i'nold' en gageable withsaid'arbor to accurately .register the core withthefmold cavity andto guide the same therein.

34. An apparatus for forming; cast articles of aluminum and like metals. comprisingan annular arbor of greater diameter than the mold cavity and provided with an inwardly extendingv lug, an anchor securedV tov and ldef pending, from said lug, means forl forming a green sand corel depending troni saidai= bor and embedding said anchor, and arcasting mold' having a` seatforv receivingv said arbor and for holding'the cone accurately positioned within the mold cavity;

35.v Anapjparatus for forming'cast' articles of aluminum and like metals, comprising an annular arbor otigreaterfdiameter than: the mold cavity andl provided with any inwardly extending part, an anchor secured to and depending from saidpart, means 'or tornr `with the molten metal.

ing a green sand core depending from said arbor and embeddingsaid anchor, and a casting mold having a seat for` receiving said arbor and for holding the core accurately positioned within the mold cavity.

36. The combination with a metallic mold having a seat therein, of an arbor having'a complementary portion for engaging said seat and a depending anchor extending therefrom, said arbor being provided with an opening adapted for admitting green sand for Y impounding a green sand core about said anchor.

37. An apparatus for forming cast articles of aluminum and like metals, comprising an arbor, means for forming a green sand core depending from and supported by said arbor, a casting mold having a seat for receiving said arbor, guiding means on said casting mold for engaging said arbor to hold the core in accurate registration with the mold cavity during the engagement of said arbor with its seat, said guiding means being detachably secured to said mold.

38. The process of forming hollow castings of aluminum andV like met-als, which consists in first forming a green sand Core upon an arbor, engaging said arbor with a seat therefor in an outer mold, whereby the core is suspended within the mold cavity of said outer mold and in filling the mold cavity 39. The process of forming hollow castings of aluminum and like metals, which consists in first impacting a green sand core in anchored relation to a supporting arbor,

engaging said arbor with a seat therefor in a preheated sectional mold, and filling said mold with molten metal through a sprue cavity provided therein and in which the molten metal is maintained iiuid until after the solidification of adjacent metal in the mold cavity.

40. The process of forming hollow castings of aluminum or like metals, which consists in first impacting a fashioned green sand core in a mold cavity and in anchored relation to an arbor for supporting the same, transferring said arbor and core to a preheated sectional outer mold, guiding said core and arbor in axial alignment with the outer mold and lowering the same into a seat for the arbor which holds the same accurately positioned axially and rotatively, and filling the mold cavity with molten f metal through a sprue connection, maintain-v ing the metal fluid therein until after the ings of aluminum and like metals, which f consists in mechanically impacting a green sand core in a fashioned mold cavity and in anchored relation to an arbor. for supporting' the same, transferring said arbor and vsuspended core into axial alignment with the mold cavity of a preheated sectional outer mold having a seat for said arbor, lowering said arbor into engagement with its seat, whereby said core is suspended within said mold cavity, filling the mold with molten metal and through a sprue of v suiiicient dimensions to quickly fill the mold cavity and to maintain the metal fluid Within said sprue until after the solidiication of adjacent metal in the mold cavity, removing the casting from the mold and detaching the arbor and returning the same to receive another core.

4t2. An apparatus for the forming of cast articles of aluminum or like metals comprising a mold for a green sand core-provided with a seat for receiving a core supporting arbor, an arbor for engaging said seat, a core anchor depending from said arbor within the core mold cavity, and a sectional outer mold having a corresponding seat for said arbor and for holding the core suspended therefrom accurately positioned within the vmold cavity.

43. An apparatus for forming castings of aluminum and like metals comprising an annular arbor, having asubstantially unobstructed opening therethrough, a core mold for receiving said arbor provided with means for accurately positioning the same, an anchor depending from said arbor within the mold cavity and around which the sand entering through said annular arbor is impacted, and a casting mold for receiving theV arbor and its depending core provided with corresponding means for accurately positioning the same.

In testimony whereof, l hereunto affix my signature.

DANIEL J. RYAN. 

